Coating material for gas barrier, gas barrier film, and laminated body

ABSTRACT

A coating material for a gas barrier includes polycarboxylic acid, a polyamine compound, a polyvalent metal compound, and a base, in which (molar number of —COO— groups included in the polycarboxylic acid)/(molar number of amino groups included in the polyamine compound)=100/20 to 100/90.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. patent application Ser. No.15/328,252, filed on Jan. 23, 2017, now U.S. Pat. No. 10,995,224, whichis a U.S. national stage application of PCT/JP2015/071113, filed on Jul.24, 2015, which in turn claims priority to Japanese Patent ApplicationNo. 2014-156311, filed on Jul. 31, 2014, the entire contents of all ofwhich are hereby incorporated by reference.

TECHNICAL FIELD

The present invention relates to a coating material for a gas barrier, agas barrier film, and a laminated body.

BACKGROUND ART

In general, as gas barrier material against oxygen, water vapor, or thelike, a gas barrier film where an inorganic oxide is deposited on asubstrate surface which is formed of a biaxial stretching polyester filmwhich is excellent in transparency and rigidness is used.

However, in a case of using such a gas barrier film using an inorganicoxide as a gas barrier film for wrapping as it is, since the depositedlayer is weak against friction and the like, during printing inpost-processing, during laminating, or when filling content therein,cracks in the deposited film may be caused by scratching or stretchingand the gas barrier property may deteriorate.

Thus, a method of laminating polyvinyl alcohol and an ethylene-vinylalcohol copolymer on a biaxial stretching film substrate as a gasbarrier film (for example, Patent Document 1), a method of addingcross-linking agent components such as an isocyanate compound topolyacrylic acid (for example, Patent Document 2), and the like havebeen proposed.

Furthermore, in recent years, a gas barrier film which uses anammonia-neutralized polycarboxylic acid, polyamine, and a swellableflaky-type inorganic compound has been proposed (for example, PatentDocument 3).

RELATED DOCUMENT Patent Document

-   -   [Patent Document 1] Japanese Unexamined Patent Publication No.        60-157830    -   [Patent Document 2] Japanese Unexamined Patent Publication No.        2001-310425    -   [Patent Document 3] Japanese Unexamined Patent Publication No.        2013-59930

SUMMARY OF THE INVENTION

However, for a gas barrier film formed by laminating polyvinyl alcoholand an ethylene-vinyl alcohol copolymer as described in Patent Document1, the oxygen barrier property may deteriorate when set under highhumidity. In addition, not only there is a problem with the productivitysince heating at a high temperature over a long period is necessary inorder to increase the gas barrier property of the film by allowing theesterification to sufficiently proceed, but there is also a problem inthat the film is colored and the appearance is poor. Furthermore, evenin the invention as described in Patent Document 2, there is a problemin that a process at a high temperature over a long period is necessaryand there is a tendency for the film to be colored.

In addition, in the technique described in Patent Document 3, since aswellable flaky-type inorganic compound is used, there is a concern thatthe appearance will be whitened, the surface unevenness will be large,and the barrier film will be weak and easily break depending on thedispersion state or a blending ratio.

The present inventors researched means for solving the problems anddiscovered that, when combining a polyamine compound, a polycarboxylicacid, a polyvalent metal compound, and a base, a measurement such as theratio of the molar number of amino groups included in the polyaminecompound and the molar number of —COO— groups included in thepolycarboxylic acid is effective as an index for evaluating the gasbarrier property. Therefore, as a result of further research, it wasdiscovered that it is possible to obtain a favorable gas barrierproperty by setting the ratio of the molar number of amino groupsincluded in the polyamine compound and the molar number of —COO— groupsincluded in the polycarboxylic acid to be within a specific range,thereby completing the present invention.

The present invention provides

[1] A coating material for a gas barrier including a polycarboxylicacid; a polyamine compound; a polyvalent metal compound; and a base, inwhich (molar number of —COO— groups included in the polycarboxylicacid)/(molar number of amino groups included in the polyaminecompound)=100/20 to 100/90.

In addition, the present invention provides

[2] The coating material for a gas barrier according to [1], in which (achemical equivalent of —COO— groups included in the polycarboxylicacid)/(a chemical equivalent of polyvalent metal contained in thepolyvalent metal compound)=100/0.1 to 100/80,

[3] The coating material for a gas barrier according to [1] or [2], inwhich the polycarboxylic acid includes at least one selected frompolyacrylic acid, polymethacrylic acid, and a copolymer of acrylic acidand methacrylic acid,

[4] The coating material for a gas barrier according to any one of [1]to [3], in which the polyvalent metal compound includes a divalent orhigher valency metal compound,

[5] The coating material for a gas barrier according to [4], in whichthe polyvalent metal compound includes one type or two or more types ofdivalent metal compound selected from magnesium oxide, calcium oxide,barium oxide, zinc oxide, magnesium hydroxide, calcium hydroxide, bariumhydroxide, and zinc hydroxide,

[6] The coating material for a gas barrier according to any one of [1]to [5], in which the polyamine compound includes a polyethylene imine,

[7] The coating material for a gas barrier according to any one of [1]to [6], in which the base includes ammonia,

[8] A gas barrier film formed of a cured product of the coating materialfor a gas barrier according to any one of [1] to [7], [9] The gasbarrier film according to [8], in which, in an infrared absorptionspectrum of the gas barrier film, when a total peak area in a range ofan absorption band of equal to or more than 1493 cm⁻¹ and equal to orless than 1780 cm⁻¹ is A and a total peak area in a range of anabsorption band of equal to or more than 1598 cm⁻¹ and equal to or lessthan 1690 cm⁻¹ is B, an area ratio of an amide bond which is indicatedby B/A is 0.370 or more,

[10] The gas barrier film according to [9], in which, in an infraredabsorption spectrum of the gas barrier film, when a total peak area in arange of an absorption band of equal to or more than 1690 cm⁻¹ and equalto or less than 1780 cm⁻¹ is C, an area ratio of carboxylic acid whichis indicated by C/A is 0.400 or less,

[11] The gas barrier film according to [9] or [10], in which, in aninfrared absorption spectrum of the gas barrier film, when a total peakarea in a range of an absorption band of equal to or more than 1493 cm⁻¹and equal to or less than 1598 cm⁻¹ is D, an area ratio of carboxylatewhich is indicated by D/A is 0.600 or less,

[12] The gas barrier film according to any one of [8] to [11], in which,when the gas barrier film is cut into 5 cm squares and mounted on asurface plate and a maximum gap generated between the gas barrier filmand the surface plate is set as an amount of warpage, the amount ofwarpage at 23° C. measured by a thickness gauge is 5 mm or less,

[13] A laminated body including a substrate layer and a gas barrier filmlayer provided on at least one surface of the substrate layer and formedof the gas barrier film according to any one of [8] to [12],

[14] A method for manufacturing a laminated body including a step ofapplying the coating material for a gas barrier according to any one of[1] to [7] on a substrate layer; a step of forming a gas barrier filmlayer by drying and curing the coating material for a gas barrier; and astep of applying a heating treatment to the gas barrier film layer,

[15] A method for manufacturing the coating material for a gas barrieraccording to any one of [1] to [7] including a step of completely orpartially neutralizing carboxy groups of the polycarboxylic acid byadding a base to the polycarboxylic acid; a step of mixing a polyvalentmetal salt compound in an obtained mixture to form a metal salt in allor some of the carboxy groups of the polycarboxylic acid neutralizedwith the base and in the carboxy groups of the polycarboxylic acid notneutralized with the base; and a step of further mixing a polyaminecompound in the obtained mixture.

The present invention provides a film where a gas barrier property,particularly an oxygen barrier property, is favorable under conditionsof both low humidity and high humidity, a coating material for a gasbarrier which is able to form a film layer, a gas barrier film whichuses the same, and a laminated body thereof.

DESCRIPTION OF EMBODIMENTS

Description will be given below of embodiments of the present invention.Here, unless otherwise specifically stated, “to” between the numbers inthe sentences represents the equal to or more than first number andequal to or less than the second number.

<Coating Material for Gas Barrier>

The coating material for a gas barrier includes polycarboxylic acid, apolyamine compound, a polyvalent metal compound, and a base, in which (amolar number of —COO— groups included in the polycarboxylic acid)/(amolar number of amino groups included in the polyamine compound)=100/20to 100/90.

The polycarboxylic acid has two or more carboxy groups in the molecule.Specifically, examples thereof include a homopolymer of α,β-unsaturatedcarboxylic acid such as acrylic acid, methacrylic acid, itaconic acid,fumaric acid, crotonic acid, cinnamic acid, 3-hexenoic acid, and3-hexenedioic acid, or a copolymer thereof. In addition, the copolymermay be a copolymer of the α,β-unsaturated carboxylic acid describedabove and esters such as ethyl ester, olefins such as ethylene, or thelike. Among these, a homopolymer of acrylic acid, methacrylic acid,itaconic acid, fumaric acid, crotonic acid, and cinnamic acid or acopolymer thereof is preferable, at least one selected from polyacrylicacid, polymethacrylic acid, and a copolymer of acrylic acid andmethacrylic acid is more preferable, at least one selected frompolyacrylic acid and polymethacrylic acid is even more preferable, and ahomopolymer of acrylic acid or a homopolymer of methacrylic acid is evenmore preferable.

Here, in the present embodiment, polyacrylic acid includes both ahomopolymer of acrylic acid and a copolymer of acrylic acid and anothermonomer. In a case of a copolymer of acrylic acid and another monomer,the polyacrylic acid generally includes constituent units which arederived from acrylic acid at 90 mass % or more in 100 mass % of thepolymer, preferably 95 mass % or more, and more preferably 99 mass % ormore.

In addition, in the present embodiment, polymethacrylic acid includesboth a homopolymer of methacrylic acid and a copolymer of methacrylicacid and another monomer. In a case of a copolymer of methacrylic acidand another monomer, the polymethacrylic acid generally includesconstituent units which are derived from methacrylic acid at 90 mass %or more in 100 mass % of polymer, preferably 95 mass % or more, and morepreferably 99 mass % or more.

Polycarboxylic acid is a polymer where carboxylic acid monomers arepolymerized and the molecular weight of the polycarboxylic acid ispreferably 50 to 5,000,000 from the point of view of obtaining asuperior gas barrier property and more preferably 100 to 4,000,000.Furthermore, 500 to 3,000,000 is preferable.

Here, in the present embodiment, the molecular weight of thepolycarboxylic acid is the polyethylene oxide conversion weight averagemolecular weight and is measurable using gel permeation chromatography(GPC).

It is possible to suppress gelation from occurring by neutralizing thepolycarboxylic acid with a base when mixing a polyamine compound andpolycarboxylic acid. Accordingly, in the polycarboxylic acid, from thepoint of view of prevention of gelation, a partially neutralized productor a completely neutralized product of a carboxy group is made using abase. It is possible to obtain the neutralized product by partially orcompletely neutralizing the carboxy group of polycarboxylic acid withabase (that is, the carboxy group of the polycarboxylic acid ispartially or completely made into carboxylate). Due to this, it ispossible to prevent gelation when adding a polyamine compound or apolyvalent metal compound.

A partially neutralized product is prepared by adding a base to anaqueous solution of polycarboxylic acid polymer and it is possible toset a desired neutralization degree by adjusting the ratio of theamounts of the polycarboxylic acid and the base. In the presentembodiment, the neutralization degree of polycarboxylic acid by the baseis preferably 30 to 100 equivalent % from the point of view ofsufficiently suppressing gelation caused by the neutralization reactionwith an amino group of a polyamine compound, and more preferably 50 to100 equivalent %.

It is possible to use an arbitrary water-soluble base as a base. It ispossible to use either or both of a volatile base and a non-volatilebase as a water-soluble base; however, a volatile base which is easilyremoved when drying or curing is preferable from the point of view ofsuppressing deterioration in the gas barrier property due to a residualfree base.

Examples of volatile bases include ammonia, morpholine, alkylamine,2-dimethyl amino ethanol, N-methyl morpholine, ethylene diamine, andtertiary amines such as triethyl amine, an aqueous solution thereof or amixture thereof. From the point of view of obtaining a favorable gasbarrier property, an ammonia aqueous solution is preferable.

Examples of non-volatile bases include sodium hydroxide, lithiumhydroxide, and potassium hydroxide, an aqueous solution thereof, or amixture thereof.

A polyamine compound is a polymer which has two or more aminos in themain chain, a side chain, or a terminal. In detail, examples thereofinclude aliphatic polyamines such as polyallyl amine, polyvinyl amine,polyethylene imine, and poly(trimethylene imine); polyamides which haveamino groups on a side chain such as polylysine and polyarginine; andthe like. In addition, the polyamine compound may be a polyamine wheresome amino groups are modified. From the point of view of obtaining afavorable gas barrier property, a polyethylene imine is more preferable.

The weight average molecular weight of the polyamine compound ispreferably 50 to 5,000,000 from the point of view of improving the gasbarrier property, more preferably 100 to 4,000,000, and even morepreferably 200 to 3,000,000.

Here, in the present embodiment, it is possible to measure the molecularweight of the polyamine compound using an ebullioscopic method orviscometry.

A polyvalent metal compound is a metal and a metal compound whichbelongs to Group 2 to 13 in the periodic table and, in detail, adivalent or higher valency metal such as magnesium (Mg), calcium (Ca),strontium (Sr), barium (Ba), iron (Fe), cobalt (Co), nickel (Ni), copper(Cu), zinc (Zn), and aluminum (Al), and oxides, hydroxides, halogenides,carbonates, phosphates, phosphites, hypophosphites, sulfates, orsulfites of these metals, or the like. From the point of view of waterresistance, impurities, and the like, a metal oxide or a metal hydroxideis preferable.

Among the divalent or higher valency metals described above, Mg, Ca, Zn,Ba, Al, and particularly Zn are preferable. In addition, among the metalcompounds described above, a divalent or higher valency metal compoundis preferable, and a divalent metal compound such as magnesium oxide,calcium oxide, barium oxide, zinc oxide, magnesium hydroxide, calciumhydroxide, barium hydroxide, and zinc hydroxide are more preferable.

Regarding these polyvalent metal compounds, it is sufficient if at leastone type is used and the polyvalent metal compound may be one type ortwo or more types.

In the present embodiment, (molar number of —COO— groups included inpolycarboxylic acid)/(molar number of amino groups included in apolyamine compound) is 100/20 or more, preferably 100/25 or more, morepreferably 100/29 or more, even more preferably 100/35 or more, andparticularly preferably 100/40 or more. By setting (molar number of—COO— groups included in polycarboxylic acid)/(molar number of aminogroups included in a polyamine compound) to be 100/20 or more, asufficient gas barrier property is obtained even under high humidity.

On the other hand, (molar number of —COO— groups included inpolycarboxylic acid)/(molar number of amino groups included in apolyamine compound) is 100/90 or less, preferably 100/85 or less, morepreferably 100/65 or less, even more preferably 100/55 or less, evenmore preferably 100/50 or less, and particularly preferably 100/45 orless. By setting (molar number of —COO— groups included inpolycarboxylic acid)/(molar number of amino groups included in apolyamine compound) to be 100/90 or less, a sufficient gas barrierproperty is obtained even under low humidity.

Details of the reason are not clear; however, it is considered that itis possible to obtain a gas barrier film or a gas barrier film layerwhich has a gas barrier property which is excellent under both highhumidity and low humidity by forming a well-balanced fine structure byamide cross-linking using amino groups which form a polyamine compoundand metal cross-linking using polyvalent metals which form a salt ofpolycarboxylic acid and polyvalent metal.

In addition, (a chemical equivalent of —COO— groups included in thepolycarboxylic acid)/(a chemical equivalent of polyvalent metalcontained in the polyvalent metal compound) is preferably 100/0.1 ormore, more preferably 100/1 or more, even more preferably 100/5 or more,even more preferably 100/8 or more, and particularly preferably 100/13or more. Due to this, it is possible to more effectively obtain a gasbarrier property under high humidity and under low humidity.

On the other hand, (a chemical equivalent of —COO— groups included inthe polycarboxylic acid)/(a chemical equivalent of polyvalent metalcontained in the polyvalent metal compound) is preferably 100/80 orless, more preferably 100/70 or less, even more preferably 100/60 orless, even more preferably 100/40 or less, and particularly preferably100/20 or less. Due to this, it is possible to more effectively obtain agas barrier property under high humidity and under low humidity.

Here, in the present embodiment, the chemical equivalent has the meaningof a molar equivalent.

The coating material for a gas barrier may include other additive agentswithin a range in which the object of the present invention is notadversely affected. For example, various types of additive agents suchas a lubricant, a slipping agent, an anti-blocking agent, an anti-staticagent, an anti-fogging agent, a pigment, a dye, and an inorganic ororganic filler may be added and various types of surfactants and thelike may be added beforehand in order to improve the wettability with asubstrate layer which will be described below. Examples of thesurfactant include an anionic surfactant, a nonionic surfactant, acationic surfactant, and an amphoteric surfactant, and a nonionicsurfactant is preferable from the point of view of obtaining a favorablecoating property, and polyoxyethylene alkyl ether is more preferable.

<Method for Manufacturing Coating Material for Gas Barrier>

In order to obtain a coating material for a gas barrier in the presentembodiment, it is important to tightly control each factor such as theselection of material, the mixing amount of material, the adjustment ofsolution concentration, and the mixing order in a mixed liquid.

For example, it is possible to manufacture the coating material for agas barrier as follows.

Firstly, carboxy groups of polycarboxylic acid are completely orpartially neutralized by adding a base to polycarboxylic acid. Apolyvalent metal salt compound is further mixed therein and a metal saltis formed in all or some of the carboxy groups of the polycarboxylicacid neutralized with the base and the carboxy groups of thepolycarboxylic acid not neutralized with the base described above. Afterthat, the coating material for a gas barrier is obtained by furtheradding a polyamine compound.

More details are as follows.

Firstly, a completely or partially neutralized solution of carboxygroups which form the polycarboxylic acid is prepared.

Subsequently, a base is added thereto and the carboxy groups ofpolycarboxylic acid are completely neutralized or partially neutralized.By neutralizing the carboxy groups of the polycarboxylic acid, gelationwhich is generated by the reaction of carboxy groups which formpolycarboxylic acid and amino groups which form a polyamine compoundwhen adding a polyvalent metal compound or a polyamine compound iseffectively prevented and it is possible to obtain an uniform gasbarrier film.

Subsequently, a polyvalent metal compound is added thereto and dissolvedand a polyvalent metal salt with —COO— groups which form polycarboxylicacid is formed by the polyvalent metal ions which are produced. At thistime, the —COO— groups which form a salt with the polyvalent metal ionsrefer to both carboxy groups which are not neutralized with the base and—COO— groups which are neutralized with a base described above. In acase of the —COO— groups which are neutralized with a base, polyvalentmetal ions which are derived from the polyvalent metal compounddescribed above are replaced and oriented to form a polyvalent metalsalt of a —COO— group. Then, it is possible to obtain the coatingmaterial for a gas barrier by further adding a polyamine compound afterforming a polyvalent metal salt.

A gas barrier film layer is formed by applying the coating material fora gas barrier produced in this manner on a substrate layer and carryingout drying and curing. At this time, a polyvalent metal of a polyvalentmetal salt of —COO— groups which form a polycarboxylic acid forms metalcross-links, and amide cross-links are formed by amino groups which formthe polyamine to obtain a gas barrier film layer which has an excellentgas barrier property.

In addition, a polyamine compound is added thereto and a mixed solutionis prepared so as to satisfy (a molar number of —COO— groups included inthe polycarboxylic acid described above)/(a molar number of amino groupsincluded in the polyamine compound described above)=100/20 to 100/90 inthe polycarboxylic acid and the polyamine compound. Furthermore, it ispreferable that (a chemical equivalent of —COO— groups included in thepolycarboxylic acid)/(a chemical equivalent of polyvalent metalcontained in the polyvalent metal compound)=100/0.1 to 100/80 from thepoint of view of improving the gas barrier property by metalcross-linking.

Due to this, when (the molar number of —COO— groups included in thepolycarboxylic acid described above)/(the molar number of amino groupsincluded in the polyamine compound described above)=100/20 to 100/90, itis possible to obtain a gas barrier property under conditions of bothunder low humidity and under high humidity, particularly, a gas barrierproperty in which the oxygen barrier property is favorable.

<Laminated Body>

A laminated body has a gas barrier film layer formed by applying andcuring a coating material for a gas barrier on a substrate layer.

It is possible to use a substrate layer without being particularlylimited as long as it is possible to apply a solution of the coatingmaterial for a gas barrier thereon. Examples thereof include organicmaterials such as a thermosetting resin, a thermoplastic resin, orpaper, inorganic materials such as glass, potter, ceramic, siliconoxide, silicon oxynitride, silicon nitride, and cement, or metals suchas aluminum, aluminum oxide, iron, copper, and stainless steel, asubstrate layer with a multilayer structure which is formed of acombination of organic materials or of organic materials and inorganicmaterials, and the like. Among these, for example, in the case ofvarious types of film uses such as wrapping material or panels, aplastic film which uses a thermosetting resin and a thermoplastic resinor an organic material such as paper is preferable. In addition, fromthe point of view of obtaining an excellent gas barrier property, thesubstrate layer is preferably formed of a thermoplastic resin which hasone type or two or more types of layers of aluminum, aluminum oxide,silicon nitride, and silicon oxynitride, and more preferably formed of athermoplastic resin which has at least one type of layer of aluminum andaluminum oxide.

As a thermosetting resin, it is possible to use a thermosetting resinknown in the art. Examples thereof include an epoxy resin, anunsaturated polyester resin, a phenol resin, a urea melamine resin, apolyurethane resin, a silicone resin, a polyimide, and the like.

As a thermoplastic resin, it is possible to use a thermoplastic resinknown in the art. Examples thereof include polyolefin (polyethylene,polypropylene, poly(4-methyl-1-pentene), poly(l-butene), and the like),polyester (polyethylene terephthalate, polybutylene terephthalate,polyethylene naphthalate, and the like), polyamide (nylon-6, nylon-66,polymetaxylene adipamide, and the like), polyvinyl chloride, polyimide,an ethylene-vinyl acetate copolymer or a saponified product thereof,polyvinyl alcohol, polyacrylonitrile, polycarbonate, polystyrene,ionomers, a fluorine resin, a mixture thereof, and the like.

Among these, from the point of view of making the transparencyfavorable, polypropylene, polyethylene terephthalate, polyethylenenaphthalate, polyamide, polyimide, and the like are preferable.

In addition, a substrate layer formed of a thermoplastic resin may be asingle layer or may be layers of two or more types according to the useof the gas barrier film.

In addition, the film formed of the thermosetting resin andthermoplastic resin described above may be stretched at least in onedirection, preferably in a biaxial direction, to make the substratelayer.

In addition, an inorganic compound such as aluminum, zinc, or silica,oxides thereof, or the like may be deposited on the surface of thesubstrate layer and polyvinylidene chloride, polyvinyl alcohol, anethylene-vinyl alcohol copolymer, an acryl resin, a urethane-basedresin, and the like may be coated thereon.

In addition, a substrate layer may be subjected to a surface treatmentin order to improve the adhesiveness with the gas barrier film. Indetail, a surface activation treatment such as a corona treatment, aflame treatment, a plasma treatment, an undercoat treatment, a primercoat treatment, a flame treatment, or the like may be performed.

The thickness of the substrate layer is preferably 1 to 1000 μm from thepoint of view of obtaining favorable film characteristics, morepreferably 1 to 500 μm, and even more preferably 1 to 300 μm.

The shape of the substrate layer is not particularly limited; however,examples thereof include a sheet or film shape and the shapes of a tray,a cup, a hollow body, and the like.

In addition, an adhesive agent layer may be provided between a substratelayer and a gas barrier film layer.

It is sufficient if the adhesive agent layer includes an adhesive agentknown in the art. Examples of the adhesive agent include a laminateadhesive agent which is composed of an organic titanium-based resin, apolyethylene imine-based resin, a urethane-based resin, an epoxy-basedresin, an acryl-based resin, a polyester-based resin, an oxazolinegroup-containing resin, a modified silicone resin, alkyl titanate,polyester-based polybutadiene, and the like, one pack type or two packtype polyol and polyvalent isocyanate, water-based urethane, ionomer,and the like. Alternatively, an aqueous adhesive agent which has anacryl-based, vinyl acetate-based, urethane-based, or polyester resin andthe like as the main raw material may be used.

In addition, according to the use of the gas barrier film, otheradditives such as a curing agent and a silane coupling agent may beadded to the adhesive agent. In a case where the use of the gas barrierfilm is for hydrothermal treatment of a retort or the like, from thepoint of view of the heat resistance or water resistance, an adhesiveagent for a dry laminate which is represented by a polyurethane-basedadhesive agent is preferable, and a solvent-based two-liquid curing typepolyurethane-based adhesive agent is more preferable.

<Gas Barrier Film>

The gas barrier film is formed of a coating material for a gas barrierand is obtained by performing a drying and heating treatment afterapplying a coating material for a gas barrier on a substrate layer,curing the coating material for a gas barrier, and forming a gas barrierfilm layer. That is, the gas barrier film is obtained by curing thecoating material for a gas barrier.

The oxygen permeability at 20° C. and 90% RH at a thickness of 1 μm ofthe gas barrier film is preferably 5 ml/m²·day·MPa or less, and morepreferably 2 ml/m²·day·MPa or less. Due to this, it is possible toobtain a favorable gas barrier property.

Here, on the basis of JIS K 7126, the oxygen permeability is measuredunder the conditions of a temperature of 20° C. and humidity of 90% RH.

In addition, in an infrared absorption spectrum of a gas barrier film ora gas barrier film layer according to the present embodiment, when atotal peak area in a range of an absorption band of equal to or morethan 1493 cm⁻¹ and equal to or less than 1780 cm⁻¹ is A and a total peakarea in a range of an absorption band of equal to or more than 1598 cm⁻¹and equal to or less than 1690 cm⁻¹ is B, an area ratio of an amide bondwhich is indicated by B/A is preferably 0.370 or more from the point ofview of the gas barrier property, more preferably 0.400 or more, evenmore preferably 0.420 or more, and particularly preferably 0.430 ormore. In addition, the upper limit of the area ratio of the amide bondwhich is indicated by B/A is preferably 0.950 or less from the point ofview of further improving the barrier property, appearance, anddimensional stability, more preferably 0.900 or less, even morepreferably 0.800 or less, even more preferably 0.600 or less, even morepreferably 0.550 or less, and particularly preferably 0.500 or less.When the area ratio of the amide bond which is indicated by B/A is 0.950or less, since the brittleness of the layer which has amidecross-linking is low and cracks are less easily generated, it ispossible to further suppress deterioration of the barrier propertycaused by stress such as bending in the film.

In addition, in an infrared absorption spectrum of a gas barrier film ora gas barrier film layer according to the present embodiment, when atotal peak area in a range of an absorption band of equal to or morethan 1690 cm⁻¹ and equal to or less than 1780 cm⁻¹ is C, an area ratioof carboxylic acid which is indicated by C/A is preferably 0.010 or morefrom the point of view of further improving the oxygen barrier property,the appearance such as warpage, and the dimensional stability, morepreferably 0.030 or more, and particularly preferably 0.070 or more.

In addition, the upper limit of the area ratio of carboxylic acid whichis indicated by C/A described above is preferably 0.400 or less from thepoint of view of further improving the oxygen barrier property, theappearance such as warpage, and the dimensional stability, morepreferably 0.300 or less, and particularly preferably 0.250 or less.

Furthermore, in an infrared absorption spectrum of a gas barrier film ora gas barrier film layer according to the present embodiment, when atotal peak area in a range of an absorption band of equal to or morethan 1493 cm⁻¹ and equal to or less than 1598 cm⁻¹ is D, an area ratioof carboxylate which is indicated by D/A is preferably 0.150 or morefrom the point of view of further improving the oxygen barrier property,and more preferably 0.350 or more.

In addition, the upper limit of the area ratio of the carboxylate whichis indicated by D/A described above is preferably 0.600 or less from thepoint of view of further improving the balance of the gas barrierproperty, the appearance such as warpage, and the dimensional stabilityand more preferably 0.550 or less.

In an infrared absorption spectrum of the gas barrier film or the gasbarrier film layer according to the present embodiment, absorption basedon νC=O of unreacted carboxylic acid is seen in the vicinity of 1700cm⁻¹, absorption based on νC=O of an amide bond which is a cross-linkingstructure is seen in the vicinity of 1630 to 1685 cm⁻¹, and absorptionbased on νC=O of carboxylate is seen in the vicinity of 1540 to 1560cm⁻¹.

That is, in the present embodiment, it is considered that, in aninfrared absorption spectrum, the total peak area A in a range of anabsorption band of equal to or more than 1493 cm⁻¹ and equal to or lessthan 1780 cm⁻¹ represents an index of the total amount of carboxylicacid, an amide bond, and carboxylate and the total peak area B in arange of an absorption band of equal to or more than 1598 cm⁻¹ and equalto or less than 1690 cm⁻¹ represents an index of the amount of an amidebond present. Furthermore, it is considered that the total peak area Cin a range of an absorption band of equal to or more than 1690 cm⁻¹ andequal to or less than 1780 cm⁻¹ represents an index of the amount ofunreacted carboxylic acid present and the total peak area D in a rangeof an absorption band of equal to or more than 1493 cm⁻¹ and equal to orless than 1598 cm⁻¹ represents an index of the amount of carboxylatepresent, that is, of ion cross-linking of a carboxyl group and an aminogroup.

Here, in the present embodiment, it is possible to measure the totalpeak areas A to D described above with the following procedure.

Firstly, a 1 cm×3 cm measurement sample is cut out from a gas barrierfilm or a gas barrier film layer. Subsequently, an infrared absorptionspectrum of the surface of the gas barrier film or the gas barrier filmlayer is obtained by infrared total reflection measurement (an ATRmethod). The total peak areas A to D described above are calculated fromthe obtained infrared absorption spectrum in the procedures (1) to (4)below.

(1) The absorbance at 1780 cm⁻¹ and at 1493 cm⁻¹ are connected by astraight line (N), and the area surrounded by the absorption spectrum inthe range of the absorption band of equal to or more than 1493 cm⁻¹ andequal to or less than 1780 cm⁻¹ and N is set as the total peak area A.

(2) A straight line (O) is drawn down orthogonally from absorbance (Q)at 1690 cm⁻¹, an intersection point of N and O is set as P, a straightline (S) is drawn down orthogonally from absorbance (R) at 1598 cm⁻¹, anintersection point of N and S is set as T, and the area which issurrounded by the absorption spectrum in the range of an absorption bandof equal to or more than 1598 cm⁻¹ and equal to or less than 1690 cm⁻¹,the straight line S, the point T, the straight line N, the point P, thestraight line 0, the absorbance Q, and the absorbance R is set as thetotal peak area B.

(3) The area which is surrounded by the absorption spectrum in the rangeof an absorption band of equal to or more than 1690 cm⁻¹ and equal to orless than 1780 cm⁻¹, the absorbance Q, the straight line 0, the point P,and the straight line N is set as the total peak area C.

(4) The area which is surrounded by the absorption spectrum in the rangeof an absorption band of equal to or more than 1493 cm⁻¹ and equal to orless than 1598 cm⁻¹, the absorbance R, the straight line S, the point T,and the straight line N is set as the total peak area D.

Subsequently, the area ratios B/A, C/A, and D/A are obtained from theareas obtained by the method described above.

Here, it is possible to perform the measurement (infrared totalreflection: the ATR method) of the infrared absorption spectrum of thepresent embodiment, for example, under the conditions of an incidentangle of 45 degrees, room temperature, a resolution of 4 cm⁻¹, and acumulative number of 100 times by mounting a PKM-GE-S (Germanium)crystal and using an IRT-5200 apparatus manufactured by JASCOCorporation.

It is possible to control the area ratio of an amide bond which isindicated by B/A of the gas barrier film or the gas barrier film layeraccording to the present embodiment, the area ratio of carboxylic acidwhich is indicated by C/A, and the area ratio of carboxylate which isindicated by D/A by appropriately adjusting the manufacturing conditionsof the gas barrier film or the gas barrier film layer.

In the present embodiment, in particular, the blending ratio ofpolycarboxylic acid and a polyamine compound, the method for preparing acoating material for a gas barrier, and the method, the temperature, thetime, and the like of the heating treatment of the coating material fora gas barrier described above are given as factors for controlling thearea ratio of an amide bond which is indicated by B/A described above,the area ratio of carboxylic acid which is indicated by C/A describedabove, and the area ratio of carboxylate which is indicated by D/Adescribed above.

In addition, the amount of warpage at 23° C. of the gas barrier film orthe laminated body according to the present embodiment is preferably 5mm or less and more preferably 3 mm or less. Here, the amount of warpageof the gas barrier film or the laminated body is the maximum gap whichis generated between the gas barrier film or the laminated body and thesurface plate when mounting the gas barrier film or the laminated bodywhich is cut out in 5 cm squares on a surface plate and is measured by athickness gauge.

The gas barrier film or the laminated body with a small amount ofwarpage is excellent in handleability. In addition, it is possible tosuppress a positional shift with another layer when laminating the gasbarrier film or the laminated body on another layer.

<Method for Manufacturing Laminated Body>

The method for manufacturing a laminated body has a step of applying thecoating material for a gas barrier described above on a substrate layer,a step of forming a gas barrier film layer by drying and curing thecoating material for a gas barrier described above, and a step ofapplying a heating treatment to the gas barrier film layer describedabove.

The method of coating is not particularly limited and it is possible touse a general method. Examples thereof include a coating method usingvarious types of coating apparatuses known in the art such as a Meyerbar coater, an air knife coater, a gravure coater such as a directgravure coater, a gravure off set, an arc gravure coater, a gravurereverse, and a jet nozzle system, a reverse roll coater such as a topfeed reverse coater, a bottom feed reverse coater, and a nozzle feedreverse coater, a 5 roll coater, a lip coater, a bar coater, a barreverse coater, a die coater, and the like.

The coating amount (wet) is preferably 1 to 500 μm, more preferably 1 to300 and even more preferably 1 to 100 and the thickness of the gasbarrier film layer after drying and curing is preferably 0.01 to 250more preferably 0.01 to 150 and even more preferably 0.01 to 50 μm.

Regarding the drying and heating treatment, the heating treatment may beperformed after drying and the drying and heating treatments may beperformed at the same time.

The method of carrying out the drying and heating treatment is notparticularly limited; however, it is sufficient if it is possible tocure the coating material for a gas barrier. Examples thereof include amethod using convective heat transfer such as an oven and a dryer, amethod using conductive heat transfer such as a heating roller, a methodusing radiant heat transmission which uses electromagnetic waves such asan infrared ray, far infrared ray, or near infrared ray heater, a methodusing internal heat generation such as microwaves, and the like.

In a case of a heating treatment using an oven, 120° C. to 250° C. for0.01 seconds to 60 minutes is preferable, and 180° C. to 220° C. forapproximately 0.01 seconds to 60 minutes is more preferable. Due tothis, it is possible to further reduce the oxygen permeability.

In a case of continuously performing a heating treatment, treatmentusing a heating roller and a far infrared ray oven is effective. Inaddition, the heating treatment may be performed under normal pressureor under reduced pressure.

Regarding the coating material for a gas barrier, by reacting carboxylgroups of polycarboxylic acid with polyamine or a polyvalent metalcompound by carrying out a drying and heating treatment and carrying outcovalent bonding and ion cross-linking, it is possible to obtain afavorable gas barrier property even under high humidity.

The laminated body is excellent in oxygen resistance permeability (gasbarrier property) and may be favorably used as wrapping material,particularly, food wrapping material, for contents for which a high gasbarrier property is demanded, and even as various wrapping materials formedical uses, industrial uses, and the like.

Description is given above of the embodiments of the present inventionwith reference to the drawings; however, these are examples of thepresent invention and it is also possible to adopt variousconfigurations other than the above.

EXAMPLES

Description will be given below of the present invention in more detailusing Examples. However, the present invention is not limited to any oneof Examples below.

<Production of Solution (U)>

87.5 g of an ammonium acrylate aqueous solution was obtained in whichpurified water was added to the mixture of 0.76 g of zinc oxide(produced by Wako Pure Chemical Industries, Ltd.) and ammonium acrylate(produced by Toagosei Co., Ltd., product name: Aron A-30, a 30% aqueoussolution) to make a 10% solution.

Next, 12.5 g of a polyethylene imine aqueous solution was obtained inwhich purified water was added to polyethylene imine (produced by WakoPure Chemical Industries, Ltd., product name: P-70) to make a 10%solution.

Next, a mixed liquid was produced by mixing and stirring 87.5 g of theammonium acrylate aqueous solution described above and 12.5 g of thepolyethylene imine aqueous solution described above.

Furthermore, a solution (U) was produced by adding purified water suchthat the solid content concentration of the mixed liquid described abovewas 2.5% and, after stirring the solution to be uniform, mixing anactivator (produced by Kao Corporation., product name: Emulgen 120) soas to be 0.3 weight % with respect to the solid content of the mixedliquid.

<Preparation of Solution (V)>

83 g of an ammonium acrylate aqueous solution was obtained in whichpurified water was added to the mixture of 0.76 g of zinc oxide(produced by Wako Pure Chemical Industries, Ltd.) and ammonium acrylate(produced by Toagosei Co., Ltd., product name: Aron A-30, a 30% aqueoussolution) to make a 10% solution.

Next, 17 g of a polyethylene imine aqueous solution was obtained inwhich purified water was added to polyethylene imine (product name:P-70, produced by Wako Pure Chemical Industries, Ltd.) to make a 10%solution.

Next, a mixed liquid was produced by mixing and stirring 83 g of theammonium acrylate aqueous solution described above and 17 g of thepolyethylene imine aqueous solution described above.

Furthermore, a solution (V) was produced by adding purified water suchthat the solid content concentration of the mixed liquid described abovewas 2.5% and, after stirring the solution to be uniform, mixing anactivator (produced by Kao Corporation., product name: Emulgen 120) soas to be 0.3 weight % with respect to the solid content of the mixedliquid.

<Preparation of Solution (W)>

83 g of an ammonium acrylate aqueous solution was obtained in whichpurified water was added to a mixture of 1.14 g of zinc oxide (producedby Wako Pure Chemical Industries, Ltd.) and ammonium acrylate (producedby Toagosei Co., Ltd., product name: Aron A-30, a 30% aqueous solution)to make a 10% solution.

Next, 17 g of a polyethylene imine aqueous solution was obtained inwhich purified water was added to polyethylene imine (product name:P-70, produced by Wako Pure Chemical Industries, Ltd.) to make a 10%solution.

Next, a mixed liquid was produced by mixing and stirring 83 g of theammonium acrylate aqueous solution described above and 17 g of thepolyethylene imine aqueous solution described above.

Furthermore, a solution (W) was produced by adding purified water suchthat the solid content concentration of the mixed liquid described abovewas 2.5% and, after stirring the solution to be uniform, mixing anactivator (produced by Kao Corporation., product name: Emulgen 120) soas to be 0.3 weight % with respect to the solid content of the mixedliquid.

<Preparation of Solution (X)>

72.1 g of an ammonium acrylate aqueous solution was obtained in whichpurified water was added to a mixture of 0.66 g of zinc oxide (producedby Wako Pure Chemical Industries, Ltd.) and ammonium acrylate (producedby Toagosei Co., Ltd., product name: Aron A-30, a 30% aqueous solution)to make a 10% solution.

Next, 27.9 g of a polyethylene imine aqueous solution was obtained inwhich purified water was added to polyethylene imine (product name:P-70, produced by Wako Pure Chemical Industries, Ltd.) to make a 10%solution.

Next, a mixed liquid was produced by mixing and stirring 72.1 g of theammonium acrylate aqueous solution described above and 27.9 g of thepolyethylene imine aqueous solution described above.

Furthermore, a solution (X) was produced by adding purified water suchthat the solid content concentration of the mixed liquid described abovewas 2.5% and, after stirring the solution to be uniform, mixing anactivator (produced by Kao Corporation., product name: Emulgen 120) soas to be 0.3 weight % with respect to the solid content of the mixedliquid.

<Preparation of Solution (Y)>

87.5 g of an ammonium acrylate aqueous solution was obtained in whichpurified water was added to ammonium acrylate (produced by Toagosei Co.,Ltd., product name: Aron A-30, a 30% aqueous solution) to make a 10%solution.

Next, 12.5 g of a polyethylene imine aqueous solution was obtained byadding purified water to polyethylene imine (product name: P-70,produced by Wako Pure Chemical Industries, Ltd.) to make a 10% solution.

Next, a mixed liquid was produced by mixing and stirring 87.5 g of theammonium acrylate aqueous solution described above and 12.5 g of thepolyethylene imine aqueous solution described above.

Furthermore, a solution (Y) was produced by adding purified water suchthat the solid content concentration of the mixed liquid described abovewas 2.5% and, after stirring the solution to be uniform, mixing anactivator (produced by Kao Corporation., product name: Emulgen 120) soas to be 0.3 weight % with respect to the solid content of the mixedliquid.

<Preparation of Solution (Z)>

72.1 g of an ammonium acrylate aqueous solution was obtained in whichpurified water was added to ammonium acrylate (produced by Toagosei Co.,Ltd., product name: Aron A-30, a 30% aqueous solution) to make a 10%solution.

Next, 27.9 g of a polyethylene imine aqueous solution was obtained inwhich purified water was added to polyethylene imine (product name:P-70, manufactured by Wako Pure Chemical Industries, Ltd.) to make a 10%solution.

Next, a mixed liquid was produced by mixing and stirring 72.1 g of theammonium acrylate aqueous solution described above and 27.9 g of thepolyethylene imine aqueous solution described above.

Furthermore, a solution (Z) was produced by adding purified water suchthat the solid content concentration of the mixed liquid described abovewas 2.5% and, after stirring the solution to be uniform, mixing anactivator (produced by Kao Corporation., product name:

Emulgen 120) so as to be 0.3 weight % with respect to the solid contentof the mixed liquid.

Example 1

A gas barrier film was obtained by applying a liquid adjusted to asolution (U) liquid concentration of 2.5% on an easy adhesion surface ofbiaxial stretching polyethylene naphthalate of 12 μm using a Meyer barsuch that the coating amount after drying (that is, the thickness of thegas barrier film) is 0.3 μm, drying the resultant under the conditionsof a temperature of 100° C. and a time of 30 seconds using a hot airdryer, and further carrying out a heating treatment at temperature of215° C. and a time of 5 minutes in the hot air dryer after that.

The following evaluation of the obtained gas barrier films was performedand the results thereof are shown in Table 1.

Example 2

Example 2 was made in the same manner as Example 1 apart from using asolution (V) instead of the solution (U).

Example 3

Example 3 was made in the same manner as Example 2 apart from carryingout the heating treatment at 215° C. for “2 minutes” instead of “5minutes”.

Example 4

Example 4 was made in the same manner as Example 1 apart from using asolution (W) instead of the solution (U).

Example 5

Example 5 was made in the same manner as Example 1 apart from using asolution (X) instead of the solution (U).

Comparative Example 1

Comparative Example 1 was made in the same manner as Example 1 apartfrom using a solution (Y) instead of the solution (U).

Comparative Example 2

Comparative Example 2 was made in the same manner as Example 1 apartfrom using a solution (Z) instead of the solution (U).

<Evaluation Method>

(1) Oxygen Permeability [ml/(m²·day·MPa)]:

The gas barrier films which were obtained in Examples and ComparativeExamples were measured under the conditions of a temperature of 20° C.and humidity of 90% RH on the basis of JIS K 7126 using OX-TRAN 2/21produced by Mocon, Inc.

Then, the oxygen permeability for a thickness of 1 μm of the gas barrierfilm was converted by the following equation.

Conversion equation: oxygen permeability for gas barrier film thickness1 μm=oxygen permeability measurement value of gas barrier film (gasbarrier film thickness 0.3 μm)×0.3 μm.

(2) IR Area Ratio

Measurement (infrared total reflection: the ATR method) of the infraredabsorption spectrum was performed under the conditions of an incidentangle of 45 degrees, room temperature, a resolution of 4 cm⁻¹, and acumulative number of 100 times by mounting a PKM-GE-S (Germanium)crystal using an IRT-5200 apparatus manufactured by JASCO Corporation.The total peak areas A to D were calculated by analyzing the obtainedabsorption spectrum by the method described above. Then, the area ratiosB/A, C/A, and D/A were obtained from the total peak areas A to D.

(3) Amount of Warpage

The amount of warpage at 23° C. of the gas barrier films which wereobtained in Examples and Comparative Examples was determined by cuttingout the gas barrier film into 5 cm squares, and measuring the maximumgap generated between the film and the surface plate by a thicknessgauge when the films were mounted on the surface plate with thesubstrate layer-side down and all sides pressed. Examples with an amountof warpage of 5 mm or less are denoted by A and Examples with an amountof warpage of more than 5 mm are denoted by B.

(4) Appearance Evaluation of Gas Barrier Film

The appearance of the gas barrier film was visually evaluated accordingto the criteria below.

A: Coloring or particles on the surface are not observed

B: Coloring or particles on the surface are observed

TABLE 1 Molar number of —COO— groups included in polycarboxylic Oxygenpermeability IR IR IR acid/molar number of amino [ml/m² · day · MPa]area area area groups included in polyamine 1 μm ratio ratio ratiocompound/molar number of (Converted B/A C/A D/A zinc oxide 0.3 μm value)[−] [−] [−] Appearance Warpage Example 1 100/29.5/10 6.1 1.8 0.430 0.2150.355 A A Example 2 100/42.5/10 3.6 1.1 0.423 0.148 0.426 A A Example 3100/42.5/10 2.6 0.8 0.383 0.084 0.533 A A Example 4 100/42.5/15 0.6 0.20.409 0.075 0.516 A A Example 5 100/65/10 5.2 1.6 0.436 0.017 0.547 A AComparative 100/29.5/0 12.6 3.8 0.462 0.407 0.131 A A Example 1Comparative 100/65/0 11.5 3.5 0.471 0.047 0.481 A A Example 2

The gas barrier films which were obtained in Examples were excellent ingas barrier performance under high humidity and also excellent in thebalance of appearance and dimensional stability.

The present application claims priority based on Japanese PatentApplication No. 2014-156311 which was applied for on Jul. 31, 2014 andall the disclosure thereof is taken in here.

The invention claimed is:
 1. A laminated body comprising: a substratelayer; and a gas barrier film layer provided on at least one surface ofthe substrate layer, wherein the gas barrier film layer is formed of agas barrier film, wherein the gas barrier film is a cured product of acoating material for a gas barrier, wherein the coating material for agas barrier comprising a polycarboxylic acid, a polyamine compound, apolyvalent metal compound, and a base, wherein (molar number of —COO—groups included in the polycarboxylic acid)/(molar number of aminogroups included in the polyamine compound)=100/25 to 100/90 in thecoating material for a gas barrier, wherein the polyamine compoundincludes polyethylene imine, and wherein (a chemical equivalent of —COO—groups included in the polycarboxylic acid)/(a chemical equivalent ofpolyvalent metal contained in the polyvalent metal compound)=100/0.1 to100/80 in the coating material for a gas barrier, wherein the substratelayer is selected from the group consisting of a paper and a plasticfilm that contains a thermoplastic resin, wherein the thickness of thesubstrate layer is 1 to 1000 μm, wherein the oxygen permeability at 20°C. and 90% RH at a thickness of 1 μm of the gas barrier film layer is 5ml/m²·day·MPa or less, and wherein, in an infrared absorption spectrumof the gas barrier film layer, when a total peak area in a range of anabsorption band of equal to or more than 1493 cm⁻¹ and equal to or lessthan 1780 cm⁻¹ is A and a total peak area in a range of an absorptionband of equal to or more than 1598 cm⁻¹ and equal to or less than 1690cm⁻¹ is B, an area ratio of an amide bond which is indicated by B/A is0.370 or more.
 2. The laminated body according to claim 1, wherein aninorganic compound or an oxide of an inorganic compound is deposited onthe surface of the substrate layer.
 3. The laminated body according toclaim 1, wherein the polycarboxylic acid includes at least one selectedfrom the group consisting of polyacrylic acid, polymethacrylic acid, anda copolymer of acrylic acid and methacrylic acid.
 4. The laminated bodyaccording to claim 1, wherein the polyvalent metal compound includes oneor two or more of divalent or higher valency metal selected from thegroup consisting of Mg, Ca, Zn, Ba and Al.
 5. The laminated bodyaccording to claim 1, wherein the polyvalent metal compound includes oneor two or more of divalent metal compound selected from the groupconsisting of magnesium oxide, calcium oxide, barium oxide, zinc oxide,magnesium hydroxide, calcium hydroxide, barium hydroxide, and zinchydroxide.
 6. The laminated body according to claim 1, wherein the baseincludes ammonia.